Nonwoven webs with one or more repeat units

ABSTRACT

A nonwoven web for an absorbent article is provided. The nonwoven web includes a first surface and a second surface. The nonwoven web includes a repeat unit comprising a visually discernible pattern of three-dimensional features on the first surface or the second surface. The three-dimensional features comprise one or more first regions and a plurality of second regions. The one or more first regions are different than the plurality of second regions. The one or more first regions comprise a plurality of substantially linear segments. A first group of the plurality of substantially linear segments intersects with a second group of the plurality of substantially linear segments at angles of intersection. The angles of intersection are in the range of about 70 degrees to about 110 degrees.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority, under 35 U.S.C. § 119(e), to U.S.Provisional Patent Application Ser. Nos. 62/842,807 and 62/842,792, bothfiled on May 3, 2019, the entire disclosure of which is herebyincorporated by reference herein.

FIELD

The present disclosure is directed to nonwoven webs with one or morerepeat units. The present disclosure is also directed to absorbentarticles comprising one or more nonwoven webs with one or more repeatunits.

BACKGROUND

Nonwoven webs are used in many industries, including the medical,hygiene, and cleaning industries. Absorbent articles comprising nonwovenwebs are used in the hygiene industry to contain and absorb bodilyexudates (i.e., urine, bowel movements, and menses) in infants,children, and adults. Absorbent articles may include, but not be limitedto, diapers, pants, adult incontinence products, feminine care products,and absorbent pads. Various components of these absorbent articlescomprise nonwoven webs. Some example components that comprise nonwovenwebs are outer cover nonwoven materials, topsheets, waistbands, legcuffs, waist cuffs, ears, belts, and acquisition materials, for example.Consumers desire high quality nonwoven webs that function well for theirintended purpose. Texture is one aspect of nonwoven webs that consumerfind beneficial. As such, some nonwoven webs comprise texture patterns.

Visually discernible texture patterns on nonwoven webs are typicallyimparted to the nonwoven webs via processes like embossing, where theembossed texture is very regular and makes the textured or embossednonwoven web exhibit a very engineered appearance, texture, and feel.The texture of such nonwoven webs has visual and tactile propertieswhich make the structure less appealing than a more traditional wovenweb. Consumers desire nonwoven webs to have the appearance, tactileproperties, and feel of more traditional woven materials as wovenmaterials are viewed by consumers as being softer, with tactilelypleasing textures, and of high quality. As such, nonwoven webs should beimproved to reflect more characteristics of woven materials.

SUMMARY

The present disclosure provides, in part, nonwoven webs with one or morerepeat units that have the tactile properties, softness, and visualappears of woven fabrics. Stated differently, the nonwoven webs of thepresent disclosure provide a more clothlike feel and appearance comparedto previous nonwovens.

A nonwoven web of the present disclosure may comprise a visuallydiscernible pattern of three-dimensional features on a first surface ora second surface thereof, wherein the three-dimensional features maycomprise regions with a plurality of irregular varying regions. Theseirregular varying regions provide for a variation in visual, tactile,and performance properties leading to the nonwoven webs being consideredclothlike or woven material like. The performance of the nonwoven websdiscussed herein is further driven to be woven-like and natural lookingby also comprising regions of a plurality of substantially linearsegments. These two different regions of the present disclosure providefor the natural type variation found in a woven material andconsequently the nonwoven webs are viewed as having the visual, tactile,and performance properties of woven materials or woven, natural fabrics.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of the presentdisclosure, and the manner of attaining them, will become more apparentand the disclosure itself will be better understood by reference to thefollowing description of example forms of the disclosure taken inconjunction with the accompanying drawings, wherein:

FIG. 1 is a plan view of an example absorbent article in the form of ataped diaper, garment-facing surface facing the viewer, in a flatlaid-out state;

FIG. 2 is a plan view of the example absorbent article of FIG. 1,wearer-facing surface facing the viewer, in a flat laid-out state;

FIG. 3 is a front perspective view of the absorbent article of FIGS. 1and 2 in a fastened position;

FIG. 4 is a front perspective view of an absorbent article in the formof a pant;

FIG. 5 is a rear perspective view of the absorbent article of FIG. 4;

FIG. 6 is a plan view of the absorbent article of FIG. 4, laid flat,with a garment-facing surface facing the viewer;

FIG. 7 is a cross-sectional view of the absorbent article taken aboutline 7-7 of FIG. 6;

FIG. 8 is a cross-sectional view of the absorbent article taken aboutline 8-8 of FIG. 6;

FIG. 9 is a plan view of an example absorbent core or an absorbentarticle;

FIG. 10 is a cross-sectional view, taken about line 10-10, of theabsorbent core of FIG. 9;

FIG. 11 is a cross-sectional view, taken about line 11-11, of theabsorbent core of FIG. 10;

FIG. 12 is a plan view of an example absorbent article of the presentdisclosure that is a sanitary napkin;

FIG. 13 is an example of a visually discernable pattern ofthree-dimensional features for a nonwoven web with a certain firstregion % area;

FIG. 14 is an example of a visually discernable pattern ofthree-dimensional features for a nonwoven web with a certain firstregion % area;

FIG. 15 is an example of a visually discernable pattern ofthree-dimensional features for a nonwoven web with a certain firstregion % area and showing a repeat unit;

FIG. 16 illustrates the repeat unit of the visually discernable patternof three-dimensional features of FIG. 15;

FIG. 17 is an example of a visually discernable pattern ofthree-dimensional features for a nonwoven web with a certain firstregion % area and showing a repeat unit;

FIG. 18 illustrates the repeat unit of the visually discernable patternof three-dimensional features of FIG. 17; and

FIG. 19 is a photograph of a portion of a nonwoven web comprising avisually discernable pattern of three-dimensional features.

FIG. 20A is a schematic drawing illustrating a cross-section of afilament made with a primary component A and a secondary component B ina side-by-side arrangement;

FIG. 20B is a schematic drawing illustrating a cross-section of afilament made with a primary component A and a secondary component B inan eccentric sheath/core arrangement;

FIG. 20C is a schematic drawing illustrating a cross-section of afilament made with a primary component A and a secondary component B ina concentric sheath/core arrangement;

FIG. 21 is a perspective view photograph of a tri-lobal, bicomponentfiber;

FIG. 22 is a schematic representation of an example apparatus for makingthe nonwoven webs of the present disclosure;

FIG. 23 is a detail of a portion of the apparatus of FIG. 22 for bondinga portion of the nonwoven webs of the present disclosure;

FIG. 24 is a further detail of a portion of the apparatus for bonding aportion of the nonwoven webs of the present disclosure, taken fromdetail FIG. 24 in FIG. 23;

FIG. 25 is a detail of a portion of the apparatus for optionaladditional bonding of a portion of the nonwoven webs of the presentdisclosure;

FIG. 26 is a photograph of an example nonwoven web with a differentdesign than the nonwoven webs of the present disclosure;

FIG. 27 is a photograph of a portion of a forming belt with thedifferent design for forming nonwoven webs;

FIG. 28 is a cross-sectional depiction of a portion of the forming belt,taken about line 28-28 of FIG. 27;

FIG. 29 is an image of a portion of a mask utilized to at least in partcreate the forming belt of FIG. 27,

FIG. 30 is an example of a mask 400 for producing a structured formingbelt;

FIG. 31 is an example of a portion of a structured forming belt forproducing the nonwoven webs of the present disclosure;

FIG. 32 is an example nonwoven web of the present disclosure, wherein acentral portion has the visually discernible pattern shown generally inFIGS. 13-19; and

FIG. 33 is an example repeat unit boundary identification linked to thePattern Analysis Test herein.

DETAILED DESCRIPTION

Various non-limiting forms of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of the nonwoven webs with oneor more repeat units disclosed herein. One or more examples of thesenon-limiting forms are illustrated in the accompanying drawings. Thoseof ordinary skill in the art will understand that the nonwoven webs withone or more repeat units described herein and illustrated in theaccompanying drawings are non-limiting example forms and that the scopeof the various non-limiting forms of the present disclosure are definedsolely by the claims. The features illustrated or described inconnection with one non-limiting form may be combined with the featuresof other non-limiting forms. Such modifications and variations areintended to be included within the scope of the present disclosure.

Prior to a discussion of the nonwoven webs with one or more repeatunits, first absorbent articles and their features will be discussed asone possible use of the nonwoven webs. It will be understood that thenonwoven webs with one or more repeat units also have other uses inother products, such as in the medical field, the cleaning and/ordusting field, and/or the wipes field, for example.

General Description of an Absorbent Article

An example absorbent article 10 according to the present disclosure,shown in the form of a taped diaper, is represented in FIGS. 1-3. FIG. 1is a plan view of the example absorbent article 10, garment-facingsurface 2 facing the viewer in a flat, laid-out state (i.e., no elasticcontraction). FIG. 2 is a plan view of the example absorbent article 10of FIG. 1, wearer-facing surface 4 facing the viewer in a flat, laid-outstate. FIG. 3 is a front perspective view of the absorbent article 10 ofFIGS. 1 and 2 in a fastened configuration. The absorbent article 10 ofFIGS. 1-3 is shown for illustration purposes only as the presentdisclosure may be used for making a wide variety of diapers, includingadult incontinence products, pants, or other absorbent articles, such assanitary napkins and absorbent pads, for example.

The absorbent article 10 may comprise a front waist region 12, a crotchregion 14, and a back waist region 16. The crotch region 14 may extendintermediate the front waist region 12 and the back waist region 16. Thefront wait region 12, the crotch region 14, and the back waist region 16may each be ⅓ of the length of the absorbent article 10. The absorbentarticle 10 may comprise a front end edge 18, a back end edge 20 oppositeto the front end edge 18, and longitudinally extending, transverselyopposed side edges 22 and 24 defined by the chassis 52.

The absorbent article 10 may comprise a liquid permeable topsheet 26, aliquid impermeable backsheet 28, and an absorbent core 30 positioned atleast partially intermediate the topsheet 26 and the backsheet 28. Theabsorbent article 10 may also comprise one or more pairs of barrier legcuffs 32 with or without elastics 33, one or more pairs of leg elastics34, one or more elastic waistbands 36, and/or one or more acquisitionmaterials 38. The acquisition material or materials 38 may be positionedintermediate the topsheet 26 and the absorbent core 30. An outer covernonwoven material 40, such as a nonwoven web, may cover a garment-facingside of the backsheet 28. The absorbent article 10 may comprise backears 42 in the back waist region 16. The back ears 42 may comprisefasteners 46 and may extend from the back waist region 16 of theabsorbent article 10 and attach (using the fasteners 46) to the landingzone area or landing zone material 44 on a garment-facing portion of thefront waist region 12 of the absorbent article 10. The absorbent article10 may also have front ears 47 in the front waist region 12. Theabsorbent article 10 may have a central lateral (or transverse) axis 48and a central longitudinal axis 50. The central lateral axis 48 extendsperpendicular to the central longitudinal axis 50.

In other instances, the absorbent article may be in the form of a panthaving permanent or refastenable side seams. Suitable refastenable seamsare disclosed in U.S. Pat. Appl. Pub. No. 2014/0005020 and U.S. Pat. No.9,421,137. Referring to FIGS. 4-8, an example absorbent article 10 inthe form of a pant is illustrated. FIG. 4 is a front perspective view ofthe absorbent article 10. FIG. 5 is a rear perspective view of theabsorbent article 10. FIG. 6 is a plan view of the absorbent article 10,laid flat, with the garment-facing surface facing the viewer. Elementsof FIG. 4-8 having the same reference number as described above withrespect to FIGS. 1-3 may be the same element (e.g., absorbent core 30).FIG. 7 is an example cross-sectional view of the absorbent article takenabout line 7-7 of FIG. 6. FIG. 8 is an example cross-sectional view ofthe absorbent article taken about line 8-8 of FIG. 6. FIGS. 7 and 8illustrate example forms of front and back belts 54, 56. The absorbentarticle 10 may have a front waist region 12, a crotch region 14, and aback waist region 16. Each of the regions 12, 14, and 16 may be ⅓ of thelength of the absorbent article 10. The absorbent article 10 may have achassis 52 (sometimes referred to as a central chassis or central panel)comprising a topsheet 26, a backsheet 28, and an absorbent core 30disposed at least partially intermediate the topsheet 26 and thebacksheet 28, and an optional acquisition material 38, similar to thatas described above with respect to FIGS. 1-3. The absorbent article 10may comprise a front belt 54 in the front waist region 12 and a backbelt 56 in the back waist region 16. The chassis 52 may be joined to awearer-facing surface 4 of the front and back belts 54, 56 or to agarment-facing surface 2 of the belts 54, 56. Side edges 23 and 25 ofthe front belt 54 may be joined to side edges 27 and 29, respectively,of the back belt 56 to form two side seams 58. The side seams 58 may beany suitable seams known to those of skill in the art, such as buttseams or overlap seams, for example. When the side seams 58 arepermanently formed or refastenably closed, the absorbent article 10 inthe form of a pant has two leg openings 60 and a waist openingcircumference 62. The side seams 58 may be permanently joined usingadhesives or bonds, for example, or may be refastenably closed usinghook and loop fasteners, for example.

Belts

Referring to FIGS. 7 and 8, the front and back belts 54 and 56 maycomprise front and back inner belt layers 66 and 67 and front and backouter belt layers 64 and 65 having an elastomeric material (e.g.,strands 68 or a film (which may be apertured)) disposed at leastpartially therebetween. The elastic elements 68 or the film may berelaxed (including being cut) to reduce elastic strain over theabsorbent core 30 or, may alternatively, run continuously across theabsorbent core 30. The elastics elements 68 may have uniform or variablespacing therebetween in any portion of the belts. The elastic elements68 may also be pre-strained the same amount or different amounts. Thefront and/or back belts 54 and 56 may have one or more elastic elementfree zones 70 where the chassis 52 overlaps the belts 54, 56. In otherinstances, at least some of the elastic elements 68 may extendcontinuously across the chassis 52.

The front and back inner belt layers 66, 67 and the front and back outerbelt layers 64, 65 may be joined using adhesives, heat bonds, pressurebonds or thermoplastic bonds. Various suitable belt layer configurationscan be found in U.S. Pat. Appl. Pub. No. 2013/0211363.

Front and back belt end edges 55 and 57 may extend longitudinally beyondthe front and back chassis end edges 19 and 21 (as shown in FIG. 6) orthey may be co-terminus. The front and back belt side edges 23, 25, 27,and 29 may extend laterally beyond the chassis side edges 22 and 24. Thefront and back belts 54 and 56 may be continuous (i.e., having at leastone layer that is continuous) from belt side edge to belt side edge(e.g., the transverse distances from 23 to 25 and from 27 to 29).Alternatively, the front and back belts 54 and 56 may be discontinuousfrom belt side edge to belt side edge (e.g., the transverse distancesfrom 23 to 25 and 27 to 29), such that they are discrete.

As disclosed in U.S. Pat. No. 7,901,393, the longitudinal length (alongthe central longitudinal axis 50) of the back belt 56 may be greaterthan the longitudinal length of the front belt 54, and this may beparticularly useful for increased buttocks coverage when the back belt56 has a greater longitudinal length versus the front belt 54 adjacentto or immediately adjacent to the side seams 58.

The front outer belt layer 64 and the back outer belt layer 65 may beseparated from each other, such that the layers are discrete or,alternatively, these layers may be continuous, such that a layer runscontinuously from the front belt end edge 55 to the back belt end edge57. This may also be true for the front and back inner belt layers 66and 67—that is, they may also be longitudinally discrete or continuous.Further, the front and back outer belt layers 64 and 65 may belongitudinally continuous while the front and back inner belt layers 66and 67 are longitudinally discrete, such that a gap is formed betweenthem—a gap between the front and back inner and outer belt layers 64,65, 66, and 67 is shown in FIG. 7 and a gap between the front and backinner belt layers 66 and 67 is shown in FIG. 8.

The front and back belts 54 and 56 may include slits, holes, and/orperforations providing increased breathability, softness, and agarment-like texture. Underwear-like appearance can be enhanced bysubstantially aligning the waist and leg edges at the side seams 58 (seeFIGS. 4 and 5).

The front and back belts 54 and 56 may comprise graphics (see e.g., 78of FIG. 1). The graphics may extend substantially around the entirecircumference of the absorbent article 10 and may be disposed acrossside seams 58 and/or across proximal front and back belt seams 15 and17; or, alternatively, adjacent to the seams 58, 15, and 17 in themanner described in U.S. Pat. No. 9,498,389 to create a moreunderwear-like article. The graphics may also be discontinuous.

Alternatively, instead of attaching belts 54 and 56 to the chassis 52 toform a pant, discrete side panels may be attached to side edges of thechassis 22 and 24.

The nonwoven webs with the one or more repeat units may be used asnonwoven components of the belts.

Topsheet

The topsheet 26 is the part of the absorbent article 10 that is incontact with the wearer's skin. The topsheet 26 may be joined toportions of the backsheet 28, the absorbent core 30, the barrier legcuffs 32, and/or any other layers as is known to those of ordinary skillin the art. The topsheet 26 may be compliant, soft-feeling, andnon-irritating to the wearer's skin. Further, at least a portion of, orall of, the topsheet may be liquid permeable, permitting liquid bodilyexudates to readily penetrate through its thickness. A suitable topsheetmay be manufactured from a wide range of materials, such as porousfoams, reticulated foams, apertured plastic films, woven materials,nonwoven webs, woven or nonwoven webs of natural fibers (e.g., wood orcotton fibers), synthetic fibers or filaments (e.g., polyester orpolypropylene or bicomponent PE/PP fibers or mixtures thereof), or acombination of natural and synthetic fibers. The topsheet may have oneor more layers. The topsheet may be apertured (FIG. 2, element 31), mayhave any suitable three-dimensional features, and/or may have aplurality of embossments (e.g., a bond pattern). The topsheet may beapertured by overbonding a material and then rupturing the overbondsthrough ring rolling, such as disclosed in U.S. Pat. No. 5,628,097, toBenson et al., issued on May 13, 1997 and disclosed in U.S. Pat. Appl.Publication No. US 2016/0136014 to Arora et al. Any portion of thetopsheet may be coated with a skin care composition, an antibacterialagent, a surfactant, and/or other beneficial agents. The topsheet may behydrophilic or hydrophobic or may have hydrophilic and/or hydrophobicportions or layers. If the topsheet is hydrophobic, typically apertureswill be present so that bodily exudates may pass through the topsheet.

The nonwoven webs with the one or more repeat units may be used asnonwoven topsheets.

Backsheet

The backsheet 28 is generally that portion of the absorbent article 10positioned proximate to the garment-facing surface of the absorbent core30. The backsheet 28 may be joined to portions of the topsheet 26, theouter cover nonwoven material 40, the absorbent core 30, and/or anyother layers of the absorbent article by any attachment methods known tothose of skill in the art. The backsheet 28 prevents, or at leastinhibits, the bodily exudates absorbed and contained in the absorbentcore 10 from soiling articles such as bedsheets, undergarments, and/orclothing. The backsheet is typically liquid impermeable, or at leastsubstantially liquid impermeable. The backsheet may, for example, be orcomprise a thin plastic film, such as a thermoplastic film having athickness of about 0.012 mm to about 0.051 mm. Other suitable backsheetmaterials may include breathable materials which permit vapors to escapefrom the absorbent article, while still preventing, or at leastinhibiting, bodily exudates from passing through the backsheet.

Outer Cover Nonwoven Material

The outer cover nonwoven material (sometimes referred to as a backsheetnonwoven) 40 may comprise one or more nonwoven materials joined to thebacksheet 28 and that covers the backsheet 28. The outer cover nonwovenmaterial 40 forms at least a portion of the garment-facing surface 2 ofthe absorbent article 10 and effectively “covers” the backsheet 28 sothat film is not present on the garment-facing surface 2. The nonwovenwebs with the one or more repeat units may be used as the outer covernonwoven material.

Absorbent Core

As used herein, the term “absorbent core” 30 refers to the component ofthe absorbent article 10 having the most absorbent capacity and thatcomprises an absorbent material. Referring to FIGS. 9-11, in someinstances, absorbent material 72 may be positioned within a core bag ora core wrap 74. The absorbent material may be profiled or not profiled,depending on the specific absorbent article. The absorbent core 30 maycomprise, consist essentially of, or consist of, a core wrap, absorbentmaterial 72, and glue enclosed within the core wrap. The absorbentmaterial may comprise superabsorbent polymers, a mixture ofsuperabsorbent polymers and air felt, only air felt, and/or a highinternal phase emulsion foam. In some instances, the absorbent materialmay comprise at least 80%, at least 85%, at least 90%, at least 95%, atleast 99%, or up to 100% superabsorbent polymers, by weight of theabsorbent material. In such instances, the absorbent material may befree of air felt, or at least mostly free of air felt. The absorbentcore periphery, which may be the periphery of the core wrap, may defineany suitable shape, such as rectangular “T,” “Y,” “hour-glass,” or“dog-bone” shaped, for example. An absorbent core periphery having agenerally “dog bone” or “hour-glass” shape may taper along its widthtowards the crotch region 14 of the absorbent article 10.

Referring to FIGS. 9-11, the absorbent core 30 may have areas havinglittle or no absorbent material 72, where a wearer-facing surface of thecore bag 74 may be joined to a garment-facing surface of the core bag74. These areas having little or no absorbent material and may bereferred to as “channels” 76. These channels can embody any suitableshapes and any suitable number of channels may be provided. In otherinstances, the absorbent core may be embossed to create the impressionof channels. The absorbent core in FIGS. 9-11 is merely an exampleabsorbent core. Many other absorbent cores with or without channels arealso within the scope of the present disclosure.

Barrier Leg Cuffs/Leg Elastics

Referring to FIGS. 1 and 2, for example, the absorbent article 10 maycomprise one or more pairs of barrier leg cuffs 32 and one or more pairsof leg elastics 34. The barrier leg cuffs 32 may be positioned laterallyinboard of leg elastics 34. Each barrier leg cuff 32 may be formed by apiece of material which is bonded to the absorbent article 10 so it canextend upwards from a wearer-facing surface 4 of the absorbent article10 and provide improved containment of body exudates approximately atthe junction of the torso and legs of the wearer. The barrier leg cuffs32 are delimited by a proximal edge joined directly or indirectly to thetopsheet and/or the backsheet and a free terminal edge, which isintended to contact and form a seal with the wearer's skin. The barrierleg cuffs 32 may extend at least partially between the front end edge 18and the back end edge 20 of the absorbent article 10 on opposite sidesof the central longitudinal axis 50 and may be at least present in thecrotch region 14. The barrier leg cuffs 32 may each comprise one or moreelastics 33 (e.g., elastic strands or strips) near or at the freeterminal edge. These elastics 33 cause the barrier leg cuffs 32 to helpform a seal around the legs and torso of a wearer. The leg elastics 34extend at least partially between the front end edge 18 and the back endedge 20. The leg elastics 34 essentially cause portions of the absorbentarticle 10 proximate to the chassis side edges 22, 24 to help form aseal around the legs of the wearer. The leg elastics 34 may extend atleast within the crotch region 14.

The nonwoven webs with the one or more repeat units may be used asnonwoven components of the barrier leg cuffs.

Waistband

Referring to FIGS. 1 and 2, the absorbent article 10 may comprise one ormore elastic waistbands 36 or non-elastic waistband. The elasticwaistbands 36 may be positioned on the garment-facing surface 2 or thewearer-facing surface 4. As an example, a first elastic waistband 36 maybe present in the front waist region 12 near the front belt end edge 18and a second elastic waistband 36 may be present in the back waistregion 16 near the back end edge 20. The elastic waistbands 36 may aidin sealing the absorbent article 10 around a waist of a wearer and atleast inhibiting bodily exudates from escaping the absorbent article 10through the waist opening circumference. In some instances, an elasticwaistband may fully surround the waist opening circumference of anabsorbent article.

The nonwoven webs with the one or more repeat units may be used asnonwoven components of the waistband.

Acquisition Materials

Referring to FIGS. 1, 2, 7, and 8, one or more acquisition materials 38may be present at least partially intermediate the topsheet 26 and theabsorbent core 30. The acquisition materials 38 are typicallyhydrophilic materials that provide significant wicking of bodilyexudates. These materials may dewater the topsheet 26 and quickly movebodily exudates into the absorbent core 30. The acquisition materials 38may comprise one or more nonwoven webs, foams, cellulosic materials,cross-linked cellulosic materials, air laid cellulosic nonwoven webs,spunlace materials, or combinations thereof, for example. In someinstances, portions of the acquisition materials 38 may extend throughportions of the topsheet 26, portions of the topsheet 26 may extendthrough portions of the acquisition materials 38, and/or the topsheet 26may be nested with the acquisition materials 38. Typically, anacquisition material 38 may have a width and length that are smallerthan the width and length of the topsheet 26. The acquisition materialmay be a secondary topsheet in the feminine pad context. The acquisitionmaterial may have one or more channels as described above with referenceto the absorbent core 30 (including the embossed version). The channelsin the acquisition material may align or not align with channels in theabsorbent core 30. In an example, a first acquisition material maycomprise a nonwoven web and as second acquisition material may comprisea cross-linked cellulosic material.

Landing Zone

Referring to FIGS. 1 and 2, the absorbent article 10 may have a landingzone area 44 that is formed in a portion of the garment-facing surface 2of the outer cover nonwoven material 40. The landing zone area 44 may bein the back waist region 16 if the absorbent article 10 fastens fromfront to back or may be in the front waist region 12 if the absorbentarticle 10 fastens back to front. In some instances, the landing zone 44may be or may comprise one or more discrete nonwoven materials that areattached to a portion of the outer cover nonwoven material 40 in thefront waist region 12 or the back waist region 16 depending upon whetherthe absorbent article fastens in the front or the back. In essence, thelanding zone 44 is configured to receive the fasteners 46 and maycomprise, for example, a plurality of loops configured to be engagedwith, a plurality of hooks on the fasteners 46, or vice versa.

The nonwoven webs with the one or more repeat units may be used asnonwoven components of the landing zone.

Wetness Indicator/Graphics

Referring to FIG. 1, the absorbent articles 10 of the present disclosuremay comprise graphics 78 and/or wetness indicators 80 that are visiblefrom the garment-facing surface 2. The graphics 78 may be printed on thelanding zone 40, the backsheet 28, and/or at other locations. Thewetness indicators 80 are typically applied to the absorbent core facingside of the backsheet 28, so that they can be contacted by bodilyexudates within the absorbent core 30. In some instances, the wetnessindicators 80 may form portions of the graphics 78. For example, awetness indicator may appear or disappear and create/remove a characterwithin some graphics. In other instances, the wetness indicators 80 maycoordinate (e.g., same design, same pattern, same color) or notcoordinate with the graphics 78.

Front and Back Ears

Referring to FIGS. 1 and 2, as referenced above, the absorbent article10 may have front and/or back ears 47, 42 in a taped diaper context.Only one set of ears may be required in most taped diapers. The singleset of ears may comprise fasteners 46 configured to engage the landingzone or landing zone area 44. If two sets of ears are provided, in mostinstances, only one set of the ears may have fasteners 46, with theother set being free of fasteners. The ears, or portions thereof, may beelastic or may have elastic panels. In an example, an elastic film orelastic strands may be positioned intermediate a first nonwoven web anda second nonwoven web. The elastic film may or may not be apertured. Theears may be shaped. The ears may be integral (e.g., extension of theouter cover nonwoven material 40, the backsheet 28, and/or the topsheet26) or may be discrete components attached to a chassis 52 of theabsorbent article on a wearer-facing surface 4, on the garment-facingsurface 2, or intermediate the two surfaces 4, 2.

The nonwoven webs with the one or more repeat units may be used asnonwoven components of the front and back ears.

Sensors

Referring again to FIG. 1, the absorbent articles of the presentdisclosure may comprise a sensor system 82 for monitoring changes withinthe absorbent article 10. The sensor system 82 may be discrete from orintegral with the absorbent article 10. The absorbent article 10 maycomprise sensors that can sense various aspects of the absorbent article10 associated with insults of bodily exudates such as urine and/or BM(e.g., the sensor system 82 may sense variations in temperature,humidity, presence of ammonia or urea, various vapor components of theexudates (urine and feces), changes in moisture vapor transmissionthrough the absorbent articles garment-facing layer, changes intranslucence of the garment-facing layer, and/or color changes throughthe garment-facing layer). Additionally, the sensor system 82 may sensecomponents of urine, such as ammonia or urea and/or byproducts resultingfrom reactions of these components with the absorbent article 10. Thesensor system 82 may sense byproducts that are produced when urine mixeswith other components of the absorbent article 10 (e.g., adhesives,agm). The components or byproducts being sensed may be present as vaporsthat may pass through the garment-facing layer. It may also be desirableto place reactants in the absorbent article that change state (e.g.color, temperature) or create a measurable byproduct when mixed withurine or BM. The sensor system 82 may also sense changes in pH,pressure, odor, the presence of gas, blood, a chemical marker or abiological marker or combinations thereof. The sensor system 82 may havea component on or proximate to the absorbent article that transmits asignal to a receiver more distal from the absorbent article, such as aniPhone, for example. The receiver may output a result to communicate tothe caregiver a condition of the absorbent article 10. In otherinstances, a receiver may not be provided, but instead the condition ofthe absorbent article 10 may be visually or audibly apparent from thesensor on the absorbent article.

Packages

The absorbent articles of the present disclosure may be placed intopackages. The packages may comprise polymeric films and/or othermaterials. Graphics and/or indicia relating to properties of theabsorbent articles may be formed on, printed on, positioned on, and/orplaced on outer portions of the packages. Each package may comprise aplurality of absorbent articles. The absorbent articles may be packedunder compression so as to reduce the size of the packages, while stillproviding an adequate number of absorbent articles per package. Bypackaging the absorbent articles under compression, caregivers caneasily handle and store the packages, while also providing distributionsavings to manufacturers owing to the size of the packages.

Sanitary Napkin

Referring to FIG. 12, an absorbent article of the present disclosure maybe a sanitary napkin 110. The sanitary napkin 110 may comprise a liquidpermeable topsheet 114, a liquid impermeable, or substantially liquidimpermeable, backsheet 116, and an absorbent core 118. The liquidimpermeable backsheet 116 may or may not be vapor permeable. Theabsorbent core 118 may have any or all of the features described hereinwith respect to the absorbent core 30 and, in some forms, may have asecondary topsheet 119 (STS) instead of the acquisition materialsdisclosed above. The STS 119 may comprise one or more channels, asdescribed above (including the embossed version). In some forms,channels in the STS 119 may be aligned with channels in the absorbentcore 118. The sanitary napkin 110 may also comprise wings 120 extendingoutwardly with respect to a longitudinal axis 180 of the sanitary napkin110. The sanitary napkin 110 may also comprise a lateral axis 190. Thewings 120 may be joined to the topsheet 114, the backsheet 116, and/orthe absorbent core 118. The sanitary napkin 110 may also comprise afront edge 122, a back edge 124 longitudinally opposing the front edge122, a first side edge 126, and a second side edge 128 longitudinallyopposing the first side edge 126. The longitudinal axis 180 may extendfrom a midpoint of the front edge 122 to a midpoint of the back edge124. The lateral axis 190 may extend from a midpoint of the first sideedge 128 to a midpoint of the second side edge 128. The sanitary napkin110 may also be provided with additional features commonly found insanitary napkins as is known in the art.

The nonwoven webs with one or more repeat units may be used as nonwovencomponents of sanitary napkins.

Nonwoven Webs with One or More Repeat Units

The nonwoven webs with one or more repeat units, or a plurality ofrepeat units are now discussed. FIG. 13 is an example of a visuallydiscernable pattern of three-dimensional features for a nonwoven webwith a certain first region % area. FIG. 14 is an example of a visuallydiscernable pattern of three-dimensional features for a nonwoven webwith a certain first region % area. FIG. 15 is an example of a visuallydiscernable pattern of three-dimensional features for a nonwoven webwith a certain first region % area and showing a repeat unit. FIG. 16illustrates the repeat unit of the visually discernable pattern ofthree-dimensional features of FIG. 15. FIG. 17 is an example of avisually discernable pattern of three-dimensional features for anonwoven web with a certain first region % area and showing a repeatunit. FIG. 18 illustrates the repeat unit of the visually discernablepattern of three-dimensional features of FIG. 17. FIG. 19 is aphotograph of a portion of a nonwoven web comprising a visuallydiscernable pattern of three-dimensional features.

The various visually discernable patterns of three-dimensional features200 for nonwoven webs of FIGS. 13-19 may each comprise one or more firstregions 202, or a plurality of first regions 202, and a plurality ofsecond regions 204. The one or more first regions 202 may have a % areaof about 5% to about 40%, about 8% to about 35%, about 8% to about 30%,about 10% to about 25%, or about 10% to about 20%, relative to an entire% area of the nonwoven web comprising the visually discernable patternof three-dimensional features, specifically reciting all 0.1% incrementswithin the specified ranges and all ranges formed therein or thereby.The plurality of second regions 204 may have a % area of about 60% toabout 95%, about 65% to about 92%, about 70% to about 92%, about 75% toabout 90%, or about 80% to about 90%, relative to the entire % area ofthe nonwoven web comprising the visually discernable pattern ofthree-dimensional features, specifically reciting all 0.1% incrementswithin the specified ranges and all ranges formed therein or thereby.All % area measurements are according to the Pattern Analysis Testherein.

Referring to FIG. 13, the visually discernable pattern ofthree-dimensional features 200 for a nonwoven web may comprise one ormore first regions 202, or a plurality of first regions 202, and aplurality of second regions 204. The one or more first regions 202 ofFIG. 13 may have a % area of about 11%, relative to an entire % area ofthe nonwoven web comprising the visually discernible pattern ofthree-dimensional features. The plurality of second regions 204 may havea % area of about 89% relative to the entire % area of the nonwoven webcomprising the visually discernible pattern of three-dimensionalfeatures. The sum of the % areas of the one or more first regions 202and the plurality of the second regions 204 may add up to 100% or less,depending on the visually discernible pattern. In an instance when thesum is less than 100%, other features may be present, such as otherthree-dimensional features, for example.

Referring to FIG. 14, the visually discernable pattern ofthree-dimensional features 200 for a nonwoven web may comprise one ormore first regions 202, or a plurality of first regions 202, and aplurality of second regions 204. The one or more first regions 202 ofFIG. 14 may have a % area of about 20%, relative to an entire % area ofthe nonwoven web comprising the visually discernible pattern ofthree-dimensional features. The plurality of second regions 204 may havea % area of about 80% relative to the entire % area of the nonwoven webcomprising the visually discernible pattern of three-dimensionalfeatures. The sum of the % areas of the one or more first regions 202and the plurality of the second regions 204 may add up to 100% or less,depending on the visually discernible pattern. In an instance when thesum is less than 100%, other features may be present, such as otherthree-dimensional features, for example.

Referring to FIG. 15, the visually discernable pattern ofthree-dimensional features 200 for a nonwoven web may comprise one ormore first regions 202, or a plurality of first regions 202, and aplurality of second regions 204. The one or more first regions 202 ofFIG. 15 may have a % area of about 13%, relative to an entire % area ofthe nonwoven web comprising the visually discernible pattern ofthree-dimensional features. The plurality of second regions 204 may havea % area of about 87% relative to the entire % area of the nonwoven webcomprising the visually discernible pattern of three-dimensionalfeatures. The sum of the % areas of the one or more first regions 202and the plurality of the second regions 204 may add up to 100% or less,depending on the visually discernible pattern. In an instance when thesum is less than 100%, other features may be present, such as otherthree-dimensional features, for example.

Referring to FIG. 17, the visually discernable pattern ofthree-dimensional features 200 for a nonwoven web may comprise one ormore first regions 202, or a plurality of first regions 202, and aplurality of second regions 204. The one or more first regions 202 ofFIG. 17 may have a % area of about 18%, relative to an entire % area ofthe nonwoven web comprising the visually discernible pattern ofthree-dimensional features. The plurality of second regions 204 may havea % area of about 82% relative to the entire % area of the nonwoven webcomprising the visually discernible pattern of three-dimensionalfeatures. The sum of % areas of the one or more first regions 202 andthe plurality of the second regions 204 may add up to 100% or less,depending on the visually discernible pattern. In an instance when thesum is less than 100%, other features may be present, such as otherthree-dimensional features, for example.

FIGS. 15 and 17 illustrate a repeat unit 205 in dash. The repeat units205 are illustrated in FIGS. 16 and 18, respectively. Any nonwoven websof the present disclosure may have one or more repeat units or aplurality of repeat units. If more than one repeat unit is provided, therepeat units may all be the same, slightly different, or different.

Referring again to FIG. 13, as an example, the one or more first regions202, or the plurality of first regions 202, and the plurality of secondregions 204 may be different. The one or more first regions 202 maycomprise a plurality of substantially linear segments, a plurality oflinear segments, and/or a plurality of substantially linear segments anda plurality of linear segments (hereinafter referred to herein as“substantially linear segments”). The plurality of second regions 204may be free of, or substantially free of, the substantially linearsegments. The plurality of substantially linear segments may comprise afirst group 208 of the plurality of substantially linear segments 206and at least a second group 210 of the plurality of substantially linearsegments 206′. The first group 208 of the plurality of substantiallylinear segments 206 may intersect the second group 210 of the pluralityof substantially linear segments 206′ at angles of intersection. Theangles of intersection may be in the range of about 60 degrees to about120 degrees, about 70 degrees to about 110 degrees, about 80 degrees toabout 100 degrees, or about 85 degrees to about 95 degrees, specificallyreciting all 1 degree increments within the specified ranges and allranges formed therein or thereby. In certain patterns, some angles ofintersection may be different while other angles of intersection may bethe same.

At least one of the substantially linear segments 206 of the first group208 of the plurality of substantially linear segments may intersect atleast two, at least 3, at least 4, at least 5, at least 6, but less than15 of the substantially linear segments 206′ of the second group 210 ofthe plurality of substantially linear segments. Likewise, at least oneof the substantially linear segments 206′ of the second group 210 of theplurality of substantially linear segments may intersect at least two,at least 3, at least 4, at least 5, at least 6, but less than 15, orless than 25, of the substantially linear segments 206 of the firstgroup 208 of the plurality of substantially linear segments. Thesubstantially linear segments 206 in the first group 208 of theplurality of substantially linear segments may extend in a firstdirection 212, or within about 0.1 degrees to about 20 degrees, about0.1 degrees to about 15 degrees, or about 0.1 degrees to about 10degrees, from the first direction 212, specifically reciting all 0.1degree increments within the specified ranges and all ranges formedtherein or thereby. The substantially linear segments 206′ in the secondgroup 210 of the plurality of linear segments may extend in a second,different direction 214, or within about 0.1 degrees to about 20degrees, about 0.1 degrees to about 15 degrees, or about 0.1 degrees toabout 10 degrees from the second direction 214, specifically recitingall 0.1 degree increments within the specified ranges and all rangesformed therein or thereby. The first direction 212 may be perpendicularto the second direction 214. The substantially linear segments 206 inthe first group 208 may extend in different directions, although stillextending generally about the first direction 212. Likewise, thesubstantially linear segments 206′ in the second group 208 may extend indifferent directions, although still extending generally about thesecond direction 214.

Still referring to FIG. 13, the substantially linear segments 206 in thefirst group 208 may have a plurality of different lengths along thefirst direction 212, although some of the substantially linear segments206 may have the same length. The substantially linear segments 206′ inthe second group 210 may have a plurality of different lengths along thesecond direction 214, although some of the substantially linear segments206′ may have the same length. It is envisioned that some of thesubstantially linear segments 206 in the first group 208 may have thesame length as some of the substantially linear segments 206′ in thesecond group 210. The lengths of the substantially linear segments inthe first and second groups may be in the range about 2 mm to about 100mm, about 2 mm to about 80 mm, about 2 mm to about 60 mm, about 2 mm toabout 50 mm, about 2 mm to about 45 mm, or about 3 mm to about 40 mm,specifically reciting all 0.1 mm increments within the specified rangesand all ranges formed therein or thereby. The substantially linearsegments 206 in the first group 208 may have the same widths ordifferent widths. Likewise, the substantially linear segments 206′ inthe second group 210 may have the same widths or different widths. Thewidth(s) of the substantially linear segments 206 of the first group 208may be the same as or different than the width(s) of the substantiallylinear segments 206′ of the second group 210. The widths of thesubstantially linear segments 206 and 206′ may be in the range of about0.5 mm to about 3 mm, specifically reciting all 0.1 mm increments withinthe specified range.

At least some of the one or more first regions 202 may fully enclose orsurround a second region 204 to form an enclosed second region 216. Atleast some of the plurality of second regions 204 may form a peninsularshape.

The above descriptions with respect to FIG. 13 may also apply to FIGS.14-19. The nonwoven webs comprising the visually discernable patterns ofthree-dimensional elements may have a basis weight in the range of about10 gsm to about 100 gsm, about 10 gsm to about 60 gsm, about 15 gsm toabout 50 gsm, about 15 gsm to about 45 gsm, about 20 gsm to about 40gsm, about 20 gsm to about 35 gsm, about 20 gsm to about 30 gsm,according to the Basis Weight Test herein, and specifically reciting all0.1 gsm increments within the specified ranges and all ranges formedtherein or thereby.

The visually discernable pattern of three-dimensional elements may beformed in a nonwoven web by embossing, hydroentangling, or by using astructured forming belt for fiber laydown. Using embossing orhydroentangling, the first regions or the second regions may be embossedor hydroentangled to form the pattern. The structured forming belt willbe discussed further below. The nonwoven webs may form a nonwovencomponent of an absorbent article or other consumer products, such acleaning or dusting product, or a wipe, for example. The absorbentarticle (as discussed above) may comprise a liquid permeable topsheet, aliquid impermeable backsheet, and an absorbent core positioned at leastpartially intermediate the topsheet and the backsheet. The absorbentarticle may also comprise an outer cover nonwoven material in a facingrelationship with the backsheet and forming a garment-facing surface ofthe absorbent article. The nonwoven webs comprising the visuallydiscernible pattern of three-dimensional features 200 may form atopsheet, or portion thereof, an outer cover nonwoven material, orportion thereof, a portion of a wing, a portion of an ear, a portion ofa belt, a portion of leg cuff, or a portion of a waistband, for example.The nonwoven webs may also form more than one component of an absorbentarticle or other consumer product. The nonwoven webs may also be used inmedical gowns, wound dressings, and/or other medical products comprisingnonwoven components.

Irregular Varying Regions

The plurality of second regions 204 of a visually discernable pattern ofthree-dimensional features 200 on a nonwoven web may comprise about 5 toabout 150, about 10 to about 100, about 10 to about 50, about 10 toabout 40, or about 10 to about 30, irregular varying regions, accordingto the Pattern Analysis Test herein, specifically reciting all 1increments within the specified ranges and all ranges formed therein orthereby. The irregular varying regions may vary in shape and/or area.

These irregular varying regions create the impression of a natural,organic, or woven nonwoven web, which is consumer desirable. Theseirregular varying regions provide for a variation in visual, tactile,and performance properties leading to the nonwoven webs being consideredclothlike or woven material like.

Area Variability

The plurality of second regions 204 of a visually discernable pattern ofthree-dimensional features 200 on a nonwoven web may have an AreaVariability of greater than 50%, but less than 150%, of greater than70%, but less than 140%, of greater than 80%, but less than 130%, or ofgreater than 85%, but less than 125%, according to the Pattern AnalysisTest herein, specifically reciting all 1% increments within thespecified ranges and all ranges formed therein or thereby.

The area variability of the second regions create the impression of anatural, organic, or woven nonwoven web, which is consumer desirable.The area variability of the second regions provide for a variation invisual, tactile, and performance properties leading to the nonwoven websbeing considered clothlike or woven material like.

Shape Variability

The plurality of second regions 204 of a visually discernable pattern ofthree-dimensional features 200 on a nonwoven web may have an ShapeVariability of greater than 20%, but less than 120%, of greater than30%, but less than 110%, of greater than 35%, but less than 110%, or ofgreater than 40%, but less than 100%, according to the Pattern AnalysisTest herein, specifically reciting all 1% increments within thespecified ranges and all ranges formed therein or thereby.

The shape variability of the second regions create the impression of anatural, organic, or woven nonwoven web, which is consumer desirable.The shape variability of the second regions provide for a variation invisual, tactile, and performance properties leading to the nonwoven websbeing considered clothlike or woven material like.

Materials

The nonwoven webs of the present disclosure may be formed by a dry-laidprocess using short staple fibers and mechanical web formation, such asa carding process. The resulting webs may be bonded using irregularpattern thermal embossing or hydroforming/hydroentangling processes. Thenonwoven webs may also comprise cotton or other natural fibers. Thenonwoven webs of the present disclosure may also be coform webs.Coformed webs typically comprise a matrix of meltblown fibers mixed withat least one additional fibrous organic materials, such as fluff pulp,cotton, and/or rayon, for example. The coform webs may be furtherstructured by embossing or laying down the composite on a structuredbelt during a coforming process. In an instance, continuous spunbondfilaments are used in producing the nonwoven webs if the nonwoven websare being made on a structured forming belt (as described below). Thenonwoven webs may comprise continuous mono-component polymeric filamentscomprising a primary polymeric component. The nonwoven webs may comprisecontinuous multicomponent polymeric filaments comprising a primarypolymeric component and a secondary polymeric component. The filamentsmay be continuous bicomponent filaments comprising a primary polymericcomponent A and a secondary polymeric component B. The bicomponentfilaments have a cross-section, a length, and a peripheral surface. Thecomponents A and B may be arranged in substantially distinct zonesacross the cross-section of the bicomponent filaments and may extendcontinuously along the length of the bicomponent filaments. Thesecondary component B constitutes at least a portion of the peripheralsurface of the bicomponent filaments continuously along the length ofthe bicomponent filaments. The polymeric components A and B may be meltspun into multicomponent fibers on conventional melt spinning equipment.The equipment may be chosen based on the desired configuration of themulticomponent. Commercially available melt spinning equipment isavailable from Hills, Inc. located in Melbourne, Fla. The temperaturefor spinning is in the range of about 180° C. to about 230° C. Thebicomponent spunbond filaments may have an average diameter from about 6microns to about 40 microns or from about 12 microns to about 40microns, for example.

The components A and B may be arranged in either a side-by-sidearrangement as shown in FIG. 20A or an eccentric sheath/core arrangementas shown in FIG. 20B to obtain filaments which exhibit a natural helicalcrimp. Alternatively, the components A and B may be arranged in aconcentric sheath/core arrangement as shown in FIG. 20C. Additionally,the component A and B may be arranged in multi-lobal sheath/corearrangement as shown in FIG. 21. Other multicomponent fibers may beproduced by using the compositions and methods of the presentdisclosure. The bicomponent and multicomponent fibers may be segmentedpie, ribbon, islands-in-the-sea configurations, or any combinationthereof. The sheath may be continuous or non-continuous around the core.The fibers of the present disclosure may have different geometries thatcomprise round, elliptical, star shaped, rectangular, and other variousgeometries. Methods for extruding multicomponent polymeric filamentsinto such arrangements are generally known to those of ordinary skill inthe art.

A wide variety of polymers are suitable for the nonwoven webs of thepresent disclosure including polyolefins (such as polyethylene,polypropylene and polybutylene), polyesters, polyamides, polyurethanes,elastomeric materials, and the like. Examples of polymer materials thatmay be spun into filaments may comprise natural polymers.

Primary component A and secondary component B may be selected so thatthe resulting bicomponent filament provides improved nonwoven bondingand softness. Primary polymer component A may have melting temperaturewhich is lower than the melting temperature of secondary polymercomponent B.

Primary polymer component A may comprise polyethylene, polypropylene orrandom copolymer of propylene and ethylene. Secondary polymer componentB may comprise polypropylene or random copolymer of propylene andethylene. Polyethylenes may comprise linear low density polyethylene andhigh density polyethylene. In addition, secondary polymer component Bmay comprise polymers, additives for enhancing the natural helical crimpof the filaments, lowering the bonding temperature of the filaments, andenhancing the abrasion resistance, strength and softness of theresulting fabric.

Inorganic fillers, such as the oxides of magnesium, aluminum, silicon,and titanium, for example, may be added as inexpensive fillers orprocessing aides. Pigments and/or color melt additives may also beadded.

The fibers of the nonwoven webs disclosed herein may comprise a slipadditive in an amount sufficient to impart the desired haptics to thefiber. As used herein, “slip additive” or “slip agent” means an externallubricant. The slip agent when melt-blended with the resin graduallyexudes or migrates to the surface during cooling or after fabrication,hence forming a uniform, invisibly thin coating, thereby yieldingpermanent lubricating effects. The slip agent may be a fast bloom slipagent.

During the making or in a post-treatment or even in both, the nonwovenwebs of the present disclosure may be treated with surfactants or otheragents to either hydrophilize the web or make it hydrophobic. Forexample, a nonwoven web used as a topsheet may be treated with ahydrophilizing material or surfactant so as to make it permeable to bodyexudates, such as urine and menses. For other absorbent articles, thenonwoven webs may remain in their naturally hydrophobic state or madeeven more hydrophobic through the addition of a hydrophobizing materialor surfactant.

Suitable materials for preparing the multicomponent filaments of thenonwoven webs of the present disclosure may comprise PP3155polypropylene obtained from Exxon Mobil Corporation and PP3854polypropylene obtained from Exxon Mobil Corporation.

Structured Forming Belts and Process for Producing Nonwoven Webs

As mentioned above, the nonwoven webs of the present disclosure may beproduced by embossing, hydroentangling, or by using a structured formingbelt for fiber or filament laydown. The structured forming belt and theprocess of manufacture will be described now. The nonwoven webs may beformed directly on the structured forming belt with continuous spunbondfilaments in a single forming process. The nonwoven webs may assume ashape and texture which corresponds to the shape and texture of thestructured forming belt.

The present disclosure may utilize the process of melt spinning. Meltspinning may occur from about 150° C. to about 2800 or from about 190°to about 230°, for example. Fiber spinning speeds may be greater than100 meters/minute, from about 1,000 to about 10,000 meters/minute, fromabout 2,000 to about 7,000 meters/minute, or from about 2,500 to about5,000 meters/minute, for example. Spinning speeds may affect thebrittleness of the spun fiber, and, in general, the higher the spinningspeed, the less brittle the fiber. Continuous fibers may be producedthrough spunbond methods or meltblowing processes.

Referring to FIG. 22, a representative process line 330 formanufacturing some example nonwoven webs made on a structured formingbelt of the present disclosure is illustrated. The process line 330 isarranged to produce a nonwoven web of bicomponent continuous filaments,but it should be understood that the present disclosure comprehendsnonwoven webs made with monocomponent or multicomponent filaments havingmore than two components. The bicomponent filaments may or may not betrilobal.

The process line 330 may comprise a pair of extruders 332 and 334 drivenby extruder drives 331 and 333, respectively, for separately extrudingthe primary polymer component A and the secondary polymer component B.Polymer component A may be fed into the respective extruder 332 from afirst hopper 336 and polymer component B may be fed into the respectiveextruder 334 from a second hopper 338. Polymer components A and B may befed from the extruders 332 and 334 through respective polymer conduits340 and 342 to filters 344 and 345 and melt pumps 346 and 347, whichpump the polymer into a spin pack 348. Spinnerets for extrudingbicomponent filaments are generally known to those of ordinary skill inthe art.

Generally described, the spin pack 348 comprises a housing whichcomprises a plurality of plates stacked one on top of the other with apattern of openings arranged to create flow paths for directing polymercomponents A and B separately through the spinneret. The spin pack 348has openings arranged in one or more rows. The spinneret openings form adownwardly extending curtain of filaments when the polymers are extrudedthrough the spinneret. For the purposes of the present disclosure,spinnerets may be arranged to form side-by-side, eccentric sheath/core,or sheath/core bicomponent filaments as illustrated in FIGS. 20A-20C, aswell as non-round fibers, such as tri-lobal fibers as shown in FIG. 21.Moreover, the fibers may be monocomponent having one polymericcomponent, such as polypropylene, for example.

The process line 330 may comprises a quench blower 350 positionedadjacent to the curtain of filaments extending from the spinneret. Airfrom the quench air blower 350 may quench the filaments extending fromthe spinneret. The quench air may be directed from one side of thefilament curtain or both sides of the filament curtain.

An attenuator 352 may be positioned below the spinneret and receives thequenched filaments. Fiber draw units or aspirators for use asattenuators in melt spinning polymers are generally known to those ofskill in the art. Suitable fiber draw units for use in the process offorming the nonwoven webs of the present disclosure may comprise alinear fiber attenuator of the type shown in U.S. Pat. No. 3,802,817 andeductive guns of the type shown in U.S. Pat. Nos. 3,692,618 and3,423,266.

Generally described, the attenuator 352 may comprise an elongatevertical passage through which the filaments are drawn by aspirating airentering from the sides of the passage and flowing downwardly throughthe passage. A structured, endless, at least partially foraminous,forming belt 360 may be positioned below the attenuator 352 and mayreceive the continuous filaments from the outlet opening of theattenuator 352. The forming belt 360 may travel around guide rollers362. A vacuum 364 positioned below the structured forming belt 360 wherethe filaments are deposited draws the filaments against the formingsurface. Although the forming belt 360 is shown as a belt in FIG. 22, itshould be understood that the forming belt may also be in other formssuch as a drum. Details of particular shaped forming belts are explainedbelow.

In operation of the process line 330, the hoppers 336 and 338 are filledwith the respective polymer components A and B. Polymer components A andB are melted and extruded by the respective extruders 332 and 334through polymer conduits 340 and 342 and the spin pack 348. Although thetemperatures of the molten polymers vary depending on the polymers used,when polyethylenes are used as primary component A and secondarycomponent B respectively, the temperatures of the polymers may rangefrom about 190° C. to about 240° C., for example.

As the extruded filaments extend below the spinneret, a stream of airfrom the quench blower 350 at least partially quench the filaments, and,for certain filaments, to induce crystallization of molten filaments.The quench air may flow in a direction substantially perpendicular tothe length of the filaments at a temperature of about 0° C. to about 35°C. and a velocity from about 100 to about 400 feet per minute. Thefilaments may be quenched sufficiently before being collected on theforming belt 360 so that the filaments may be arranged by the forced airpassing through the filaments and the forming belt 360. Quenching thefilaments reduces the tackiness of the filaments so that the filamentsdo not adhere to one another too tightly before being bonded and may bemoved or arranged on the forming belt 360 during collection of thefilaments on the forming belt 360 and formation of the nonwoven web.

After quenching, the filaments are drawn into the vertical passage ofthe attenuator 352 by a flow of the fiber draw unit. The attenuator maybe positioned 30 to 60 inches below the bottom of the spinneret.

The filaments may be deposited through the outlet opening of theattenuator 352 onto the shaped, traveling forming belt 360. As thefilaments are contacting the forming surface of the forming belt 360,the vacuum 364 draws the air and filaments against the forming belt 360to form a nonwoven web of continuous filaments which assumes a shapecorresponding to the shape of the structured forming surface of thestructured forming belt 360. As discussed above, because the filamentsare quenched, the filaments are not too tacky and the vacuum may move orarrange the filaments on the forming belt 360 as the filaments are beingcollected on the forming belt 330 and formed into nonwoven webs.

The process line 330 may comprise one or more bonding devices such asthe cylinder-shaped compaction rolls 370 and 372, which form a nipthrough which the nonwoven web may be compacted (e.g., calendared) andwhich may be heated to bond fibers as well. One or both of compactionrolls 370, 372 may be heated to provide enhanced properties and benefitsto the nonwoven webs by bonding portions of the nonwoven webs. Forexample, it is believed that heating sufficient to provide thermalbonding improves the nonwoven web's tensile properties. The compactionrolls may be pair of smooth surface stainless steel rolls withindependent heating controllers. The compaction rolls may be heated byelectric elements or hot oil circulation. The gap between the compactionrolls may be hydraulically controlled to impose desired pressure on thenonwoven web as it passes through the compaction rolls on the formingbelt. As an example, with a forming belt caliper of 1.4 mm, and aspunbond nonwoven web having a basis weight of 25 gsm, the nip gapbetween the compaction rolls 370 and 372 may be about 1.4 mm.

An upper compaction roll 370 may be heated sufficiently to consolidateor melt fibers on a first surface of a nonwoven web 310, to impartstrength to the nonwoven web so that it may be removed from forming belt360 without losing integrity. As shown in FIGS. 23 and 24, for example,as rolls 370 and 372 rotate in the direction indicated by the arrows,the forming belt 360 with the spunbond web laid down on it enter the nipformed by rolls 370 and 372. Heated roll 370 may heat the portions ofthe nonwoven web 310 that are pressed against it by the raised resinelements of belt 360, i.e., in regions 321, to create bonded fibers 380on at least the first surface of the nonwoven web 310. As can beunderstood by the description herein, the bonded regions so formed maytake the pattern of the raised elements of forming belt 360. Byadjusting temperature and dwell time, the bonding may be limitedprimarily to fibers closest to the first surface of the nonwoven web310, or thermal bonding may be achieved to a second surface. Bonding mayalso be a discontinuous network, for example, as point bonds 390,discussed below.

The raised elements of the forming belt 360 may be selected to establishvarious network characteristics of the forming belt and the bondedregions of the nonwoven web 310. The network corresponds to resin makingup the raised elements of the forming belt 360 and may comprisesubstantially continuous, substantially semi-continuous, discontinuous,or combinations thereof options. These networks may be descriptive ofthe raised elements of the forming belt 360 as it pertains to theirappearance or make-up in the X-Y planes of the forming belt 360 or thethree-dimensional features of the nonwoven webs 310.

After compaction, the nonwoven web 310 may leave the forming belt 360and be calendared through a nip formed by calendar rolls 371, 373, afterwhich the nonwoven web 310 may be wound onto a reel 375 or conveyeddirectly into a manufacturing operation for products, such as absorbentarticles. As shown in the schematic cross-section of FIG. 25, thecalendar rolls 371, 373 may be stainless steel rolls having an engravedpattern roll 384 and a smooth roll 386. The engraved roll may haveraised portions 388 that may provide for additional compaction andbonding to the nonwoven web 310. Raised portions 388 may be a regularpattern of relatively small spaced apart “pins” that form a pattern ofrelatively small point bonds 390 in the nip of calendar rolls 371 and373. The percent of point bonds in the nonwoven web 10 may be from about3% to about 30% or from about 7% to about 20%, for example. The engravedpattern may be a plurality of closely spaced, regular, generallycylindrically-shaped, generally flat-topped pin shapes, with pin heightsbeing in a range of about 0.5 mm to about 5 mm or from about 1 mm toabout 3 mm, for example. Pin bonding calendar rolls may form closelyspaced, regular point bonds 390 in the nonwoven web 10, as shown in anexample in FIG. 26. Further bonding may be by hot-air-through bonding,for example. FIG. 26 shows a hearts pattern made by the same structuredforming belt technology that may be used to make the nonwoven webs ofthe present disclosure. FIG. 26 is only an example of a pattern,although the visually discernable patterns comprising thethree-dimensional features shown, for example, in FIGS. 13-19, are moreapplicable to the present disclosure.

“Point bonding”, as used herein, is a method of thermally bonding anonwoven web. This method comprises passing a web through a nip betweentwo rolls comprising a heated male patterned or engraved metal roll anda smooth or patterned metal roll. The male patterned roll may have aplurality of raised, generally cylindrical-shaped pins that producecircular point bonds. The smooth roll may or may not be heated,depending on the application. In a nonwoven manufacturing line, thenonwoven web, which could be a non-bonded nonwoven web, is fed into thecalendar nip and the fiber temperature is raised to the point for fibersto thermally fuse with each other at the tips of engraved points andagainst the smooth roll. The heating time is typically in the order ofmilliseconds. The nonwoven web properties are dependent on processsettings such as roll temperatures, web line speeds, and nip pressures,all of which may be determined by the skilled person for the desiredlevel of point bonding. Other types of point bonding known generally ashot calendar bonding may use different geometries for the bonds (otherthan circular shaped), such as oval, lines, circles, for example. In anexample, the point bonding produces a pattern of point bonds being 0.5mm diameter circles with 10% overall bonding area. Other bonding shapesmay have raised pins having a longest dimension across the bondingsurface of a pin of from about 0.1 mm to 2.0 mm and the overall bondingarea ranges from about 5% to about 30%, for example.

As shown in FIG. 26, a heated compaction roll 370 may form a bondpattern, which may be a substantially continuous network bond pattern380 (e.g., interconnected heart shaped bonds) on a first surface of thenonwoven web 310 (not shown in FIG. 26, as it faces away from theviewer), and the engraved calendar roll 373 may form relatively smallpoint bonds 390 on a second surface 314 of the nonwoven web. The pointbonds 390 may secure loose fibers that would otherwise be prone tofuzzing or pilling during use of the nonwoven web 310. The advantage ofthe resulting structure of the nonwoven web 310 is most evident whenused as a topsheet or outer cover nonwoven material in an absorbentarticle, such as a diaper, for example. In use, in an absorbent article,a first surface of the nonwoven web 310 may be relatively flat (relativeto second surface 14) and have a relatively large amount of bonding dueto the heated compaction roll forming bonds 380 at the areas of thenonwoven web pressed by the raised elements of the forming belt 360.This bonding gives the nonwoven web 310 structural integrity, but stillmay be relatively stiff or rough to the skin of a user. Therefore, afirst surface of the nonwoven web 310 may be oriented in a diaper orsanitary napkin to face the interior of the article, i.e., away from thebody of the wearer or garment-facing. Likewise, the second surface 314may be wearer-facing in use, and in contact with the body. Therelatively small point bonds 390 may be less likely to be perceivedvisually or tacitly by the user, and the relatively softthree-dimensional features may remain visually free of fuzzing andpilling while feeling soft to the body in use. Further bonding may beused instead of, or in addition to, the above-mentioned bonding.Through-air bonding may also be used.

The forming belt 360 may be made according to the methods and processesdescribed in U.S. Pat. No. 6,610,173, issued to Lindsay et al., on Aug.26, 2003, or U.S. Pat. No. 5,514,523, issued to Trokhan et al., on May7, 1996, or U.S. Pat. No. 6,398,910, issued to Burazin et al., on Jun.4, 2002, or U.S. Pat. No. 8,940,376, issued to Stage et al., on Jan. 27,2015, each with the improved features and patterns disclosed herein formaking spunbond nonwoven webs. The Lindsay, Trokhan, Burazin, and Stagedisclosures describe structured forming belts that are representative ofpapermaking belts made with cured resin on a woven reinforcing member,which belts, with improvements, may be utilized to form the nonwovenwebs of the present disclosure as described herein.

An example of a structured forming belt 360, and which may be madeaccording to the disclosure of U.S. Pat. No. 5,514,523, is shown in FIG.27. As taught therein, a reinforcing member 394 (such as a woven belt offilaments 396) is thoroughly coated with a liquid photosensitivepolymeric resin to a preselected thickness. A film or negative maskincorporating the desired raised element pattern repeating elements(e.g., FIG. 29) is juxtaposed on the liquid photosensitive resin. Theresin is then exposed to light of an appropriate wave length through thefilm, such as UV light for a UV-curable resin. This exposure to lightcauses curing of the resin in the exposed areas (i.e., white portions ornon-printed portions in the mask). Uncured resin (resin under the opaqueportions in the mask) is removed from the system leaving behind thecured resin forming the pattern illustrated, for example, the curedresin elements 392 shown in FIG. 27. Other patterns may also be formed,such as the patterns illustrated in FIGS. 13 to 19.

The forming belt 360 may comprise cured resin elements 392 on a wovenreinforcing member 394. The reinforcing member 394 may be made of wovenfilaments 396 as is generally known in the art of papermaking belts,including resin coated papermaking belts. The cured resin elements mayhave the general structure depicted in FIG. 27, and are made by the useof a mask 397 having the dimensions indicated in FIG. 329 As shown inschematic cross-section in FIG. 28, cured resin elements 392 flow aroundand are cured to “lock on” to the reinforcing member 394 and may have awidth at a distal end DW of about 0.020 inches to about 0.060 inches, orfrom about 0.025 inches to about 0.030 inches, and a total height abovethe reinforcing member 394, referred to as over burden, OB, of about0.030 inches to about 0.120 inches or about 0.50 inches to about 0.80inches, or about 0.040 inches. FIG. 29 represents a portion of a mask397 showing the design and representative dimensions for one repeat unitof the repeating hearts design, shown herein merely as an example. Thewhite portion 398 is transparent to UV light, and in the process ofmaking the belt, as described in U.S. Pat. No. 5,514,523, permits UVlight to cure an underlying layer of resin which is cured to form theraised elements 392 on the reinforcing member 394. After the uncuredresin is washed away, the forming belt 360 having a cured resin designas shown in FIG. 27 is produced by seaming the ends of a length of theforming belt, the length of which may be determined by the design of theapparatus, as depicted in FIG. 22.

Now that the generally process and forming belt have been described,examples of masks and forming belts of the nonwoven webs comprisingvisually discernable patterns of three-dimensional elements aredisclosed in FIGS. 30-32. FIG. 30 is an example of a mask 400 forproducing a structured forming belt. The central portion 402 of the mask400 illustrates the visually discernable patterns shown generally inFIGS. 13-19. FIG. 31 is an example of a portion of a structured formingbelt 404 for producing the nonwoven webs of the present disclosure. FIG.32 is an example nonwoven web 406 of the present disclosure, where thecentral portion 402 has the visually discernible pattern shown generallyin FIGS. 13-19.

Referring to FIG. 30, the white portions of the mask 400 will formraised areas of resin on the structured forming belt 404, while theblack portions will not be cured and will be washed away from thestructured forming belt 404. In another form, the white and blackportions could be reversed, and the visually discernible pattern wouldbe formed where cured resin is not present on the belt. FIG. 31illustrates the portion of structured forming belt pattern 404 of thecentral portion 402 of the mask 400. In this instance, the raisedportions have resin, while the other portions do not.

The nonwoven webs comprising the visually discernible patterns ofthree-dimensional elements of the present disclosure may also have othervisually discernible patterns of three-dimensional features 408, 410,412, as shown in FIGS. 30 and 32. While the other patterns may beembossed or hydroentangled, they may also be formed using the structuredforming belts described herein and process thereof. The other (orsecond, third, and fourth) visually discernible patterns ofthree-dimensional features 408, 410, and 412 may each comprise amicrozone comprising a first region 414 and a second region 416(visually discernible pattern 410 is used an example). The first region414 may be formed where black is present on the mask 400 and the secondregion 416 may be formed where white is present on the mask 400. Assuch, the first region 414 may be less densified than the second region416. The first region 414 may have an average intensive property havinga first value and the second region 416 may have the average intensiveproperty having a second value. The first value may be different thanthe second value. The average intensive property may be caliper, basisweight, or volumetric density. The other visually discernible patternsof three-dimensional features may include a different pattern of FIGS.13-19 vs. completely different pattern as shown in FIG. 32.

Referring now to the central portion 402 of the nonwoven web 406 of FIG.32, the visually discernible pattern of three-dimensional features maycomprise first regions 420 (substantially linear segments) and secondregions 422 (regions surrounding the substantially linear elements). Thefirst regions 420 may have an average intensive property having a firstvalue and the second regions 422 may have the average intensive propertyhaving a second value. The first and second values may be different. Theaverage intensive property may be caliper, basis weight, or volumetricdensity.

The nonwoven webs disclosed herein may be fluid permeable. The entirenonwoven web may be considered fluid permeable or some regions may befluid permeable. By fluid permeable, as used herein, with respect to thenonwoven web is meant that the nonwoven web has at least one regionwhich permits liquid to pass through under in-use conditions of aconsumer product or absorbent article. For example, if used as atopsheet on a disposable absorbent article, the nonwoven web may have atleast one zone having a level of fluid permeability permitting urine topass through to an underlying absorbent core. By fluid permeable as usedherein with respect to a region is meant that the region exhibits aporous structure that permits liquid to pass through.

Referring again to FIG. 32, an example nonwoven web of the presentdisclosure is illustrated. The nonwoven web has a plurality of visuallydiscernible patterns of three-dimensional elements comprising firstregions 414 and second regions 416. The first and second regions of eachof the patterns 420, 408, 410, 412 are recognizably different visually.A visually discernible difference exists if an observer in ordinaryindoor lighting conditions (20/20 vision, lighting sufficient to readby, for example) may visually discern a pattern difference between thezones, such as the first region 414 and the second region 416 of pattern410.

Because of the nature of the structured forming belts and otherapparatus elements, as described herein, the three-dimensional featuresof the nonwoven web have average intensive properties that may differbetween first and second regions, or from feature to feature in waysthat provide for beneficial properties of the nonwoven web when used inpersonal care articles, garments, medical products, and cleaningproducts. For example, a first region may have a basis weight or densitythat is different from the basis weight or density of a second region,and both may have a basis weight or density that is different from thatof a third region, providing for beneficial aesthetic and functionalproperties related to fluid acquisition, distribution and/or absorptionin diapers or sanitary napkins.

The average intensive property differential between the various regionsof the nonwoven webs is believed to be due to the fiber distribution andcompaction resulting from the apparatus and method described herein. Thefiber distribution occurs during the fiber laydown process, as opposedto, for example, a post making process such as embossing processes.Because the fibers are free to move during a process such as a meltspinning process, with the movement determined by the nature of thefeatures and air permeability of the forming belt and other processingparameters, the fibers are believed to be more stable and permanentlyformed in nonwoven web.

In structured forming belts having multiple zones, the air permeabilityin each zone may be variable such that the intensive properties ofaverage basis weight and average volumetric density in the zones may bevaried. Variable air permeabilities in the various zones causes fibermovement during laydown. The air permeability may be between about 400to about 1000 cfm, or between about 400 to about 800 cfm, or betweenabout 500 cfm and about 750 cfm, or between about 650 to about 700 cfm,specifically reciting all 1 cfm increments within the specified rangesand all ranges formed therein or thereby.

Examples/Combinations

-   1. A nonwoven web for an absorbent article, the nonwoven web    comprising:

a first surface;

a second surface; and

a repeat unit comprising:

-   -   a visually discernible pattern of three-dimensional features on        the first surface or the second surface, wherein the        three-dimensional features comprise one or more first regions        and a plurality of second regions;    -   wherein the one or more first regions are different than the        plurality of second regions;    -   wherein the one or more first regions comprise a plurality of        substantially linear segments;    -   wherein a first group of the plurality of substantially linear        segments intersects with a second group of the plurality of        substantially linear segments at angles of intersection; and    -   wherein the angles of intersection are in the range of about 70        degrees to about 110 degrees.

-   2. The nonwoven web for an absorbent article of Paragraph 1, wherein    the angles of intersection are in the range of about 80 degrees to    about 100 degrees.

-   3. The nonwoven web for an absorbent article of Paragraph 1 or 2,    wherein the plurality of second regions are free of the plurality of    substantially linear segments.

-   4. The nonwoven web for an absorbent article of any one of the    preceding Paragraphs, wherein the one or more first regions have a %    area of about 10% to about 30% relative to an entire % area of the    nonwoven web comprising the visually discernible pattern, according    to the Pattern Analysis Test.

-   5. The nonwoven web for an absorbent article of Paragraph 4, wherein    the plurality of second regions have a % area of about 70% to about    90% relative to the entire % area of the nonwoven web comprising the    visually discernable pattern, according to the Pattern Analysis    Test.

-   6. The nonwoven web for an absorbent article of any one of the    preceding Paragraphs, wherein the nonwoven web has a basis weight in    the range of about 15 gsm to about 45 gsm, according to the Basis    Weight Test.

-   7. The nonwoven web for an absorbent article of any one of the    preceding Paragraphs, wherein at least one substantially linear    segment of the first group intersects three or more other    substantially linear segments of the second group.

-   8. The nonwoven web for an absorbent article of any one of the    preceding Paragraphs, wherein the first group of the plurality of    substantially linear segments extends in a first direction or within    about 0.1 degrees to about 10 degrees of the first direction.

-   9. The nonwoven web for an absorbent article of Claim 8, wherein the    second group of the plurality of substantially linear segments    extends in a second, different direction or within about 0.1 degrees    to about 10 degrees of the second, different direction, and wherein    the first direction is transverse or substantially perpendicular to    the second direction.

-   10. The nonwoven web for an absorbent article of any one of the    preceding Paragraphs, wherein the one or more first regions have an    average intensive property having a first value, wherein the    plurality of second regions have the average intensive property    having a second, different value.

-   11. The nonwoven web for an absorbent article of Claim 10, wherein    the first average intensive property and the second average    intensive property are basis weight, caliper, or volumetric density.

-   12. The nonwoven web for an absorbent article of any one of the    preceding Paragraphs, wherein the first group of the plurality of    substantially linear segments have a plurality of different lengths.

-   13. The nonwoven web for an absorbent article of any one of the    preceding Paragraphs, wherein the second group of the plurality of    substantially linear segments have a plurality of different lengths.

-   14. The nonwoven web for an absorbent article of any one of the    preceding Paragraphs, wherein at least some of the one or more first    regions fully enclose a second region.

-   15. An absorbent article comprising the nonwoven web of any one of    the preceding Paragraphs.

-   16. The absorbent article of Paragraph 15, comprising:

a liquid permeable topsheet;

a liquid impermeable backsheet;

an absorbent core positioned intermediate the topsheet and thebacksheet; and

an outer cover nonwoven material forming a garment-facing surface of theabsorbent article.

-   17. The absorbent article of Paragraph 16, wherein the outer cover    nonwoven material comprises the nonwoven web.-   18. The absorbent article of Paragraph 16, wherein the liquid    permeable topsheet comprises the nonwoven web.-   19. A nonwoven web for an absorbent article, the nonwoven web    comprising:

a first surface;

a second surface; and

a repeat unit comprising:

-   -   a visually discernible pattern of three-dimensional features on        the first surface or the second surface, wherein the        three-dimensional features comprise one or more first regions        and a plurality of second regions, wherein the one or more first        regions are different than the plurality of second regions;    -   wherein the plurality of first regions comprise a plurality of        substantially linear segments;    -   wherein a first group of the plurality of substantially linear        segments intersects with a second group of the plurality of        substantially linear segments at angles of intersection;    -   wherein the angles of intersection are in the range of about 70        degrees to about 110 degrees;    -   wherein the first group of the plurality of substantially linear        segments comprises a plurality of different lengths; and    -   wherein the second group of the plurality of substantially        linear segments comprises a plurality of different lengths.

-   20. The nonwoven web for an absorbent article of Paragraph 19,    wherein the plurality of second regions are free of the plurality of    substantially linear segments.

-   21. An absorbent article comprising:

a liquid permeable topsheet;

a liquid impermeable backsheet;

an absorbent core positioned at least partially intermediate thetopsheet and the backsheet; and

an outer cover nonwoven material in a facing relationship with thebacksheet, the outer cover nonwoven material comprising:

-   -   a surface comprising a repeat unit comprising:        -   a visually discernible pattern of three-dimensional            features, wherein the three-dimensional features comprise            one or more first regions and a plurality of second regions;        -   wherein the one or more first regions are different than the            plurality of second regions;        -   wherein the one or more first regions comprise a plurality            of substantially linear segments;        -   wherein the plurality of second regions are free of the            plurality of substantially linear segments;        -   wherein a first group of the plurality of substantially            linear segments intersects with a second group of the            plurality of substantially linear segments at angles of            intersection;        -   wherein the angles of intersection are in the range of about            70 degrees to about 110 degrees;        -   wherein the first group of the plurality of substantially            linear segments comprises a plurality of different lengths;            and        -   wherein the second group of the plurality of substantially            linear segments comprises a plurality of different lengths.

-   22. The absorbent article of Paragraph 21, wherein one or more first    regions comprise a plurality of first regions.

-   23. A structured forming belt comprising:

an endless foraminous member comprising a first surface and a secondsurface; and

a curable resin extending from the first surface of the foraminousmember;

the resin forming a repeat unit comprising:

-   -   a visually discernible pattern of three-dimensional features,        wherein the three-dimensional features comprise one or more        first regions and a plurality of second regions, wherein the one        or more first regions comprise the resin, and wherein the        plurality of second regions are free of the resin;    -   wherein the one or more first regions are different than the        plurality of second regions;    -   wherein the one or more first regions comprise a plurality of        substantially linear segments;    -   wherein a first group of the plurality of substantially linear        segments intersects with a second group of the plurality of        substantially linear segments at angles of intersection; and    -   wherein the angles of intersection are in the range of about 70        degrees to about 110 degrees.

-   24. A nonwoven web for an absorbent article, the nonwoven web    comprising:

a first surface;

a second surface; and

a repeat unit comprising:

-   -   a visually discernible pattern of three-dimensional features on        the first surface or the second surface, wherein the        three-dimensional features comprise one or more first regions        and a plurality of second regions, and wherein the plurality of        second regions have a Shape Variability of greater than 20%, but        less than 120%, according to the Pattern Analysis Test.

-   25. The nonwoven web for an absorbent article of Paragraph 24,    wherein the plurality of second regions comprise 10 to 100 irregular    varying regions, according to the Pattern Analysis Test.

-   26. The nonwoven web for an absorbent article of Paragraph 24 or 25,    wherein the plurality of second regions have an Area Variability of    greater than 50%, but less than 150%, according to the Pattern    Analysis Test.

-   27. The nonwoven web for an absorbent article of any one of    Paragraphs 24-26, wherein at least some of the plurality of second    regions comprise a peninsular shape.

-   28. A nonwoven web for an absorbent article, the nonwoven web    comprising:

a first surface;

a second surface; and

a repeat unit comprising:

-   -   a visually discernible pattern of three-dimensional features on        the first surface or the second surface, wherein the        three-dimensional features comprise one or more first regions        and a plurality of second regions, and wherein at least some of        the plurality of second regions comprise a peninsular shape.

-   29. The nonwoven web for an absorbent article of Paragraph 28,    wherein the plurality of second regions have a Shape Variability of    greater than 20%, but less than 120%, according to the Pattern    Analysis Test.

-   30. The nonwoven web for an absorbent article of Paragraph 28 or 29,    wherein the plurality of second regions comprise 10 to 100 irregular    varying regions, according to the Pattern Analysis Test.

-   31. The nonwoven web for an absorbent article any one of Paragraphs    28-30, wherein the plurality of second regions have an Area    Variability of greater than 50%, but less than 150%, according to    the Pattern Analysis Test.

-   32. A structured forming belt comprising:

an endless foraminous member comprising a first surface and a secondsurface; and

a curable resin extending from the first surface of the foraminousmember;

the resin forming a repeat unit comprising:

-   -   a visually discernible pattern of three-dimensional features,        wherein the three-dimensional features comprise one or more        first regions and a plurality of second regions, and wherein the        plurality of second regions comprise 10 to 100 irregular varying        regions, according to the Pattern Analysis Test.

-   33. The structured forming belt of Paragraph 32, wherein the one or    more first regions comprise a plurality of substantially linear    segments that comprise the resin.

-   34. The structured forming belt of Paragraph 32 or 33, wherein the    plurality of second regions comprising the 10 to 100 irregular    varying regions have an Area Variability of greater than 50%, but    less than 150%, according to the Pattern Analysis Test.

-   35. The structured forming belt of any one of Paragraphs 32-34,    wherein the plurality of second regions comprising the 10 to 100    irregular varying regions have a Shape Variability of greater than    20%, but less than 120%, according to the Pattern Analysis Test.

-   36. The structured forming belt of any one of Paragraphs 32-35,    wherein at least some of the 10 to 100 irregular varying regions    comprise a peninsular shape.

-   37. The structured forming belt of any one of Paragraphs 32-36,    wherein the plurality of second regions comprising the 10 to 100    irregular varying regions are free of the plurality of substantially    linear segments and the resin.

-   38. The structured forming belt of any one of Paragraphs 32-37,    wherein the plurality of substantially linear segments comprise a    first group of the plurality of substantially linear segments and a    second group of the plurality of substantially linear segments,    wherein the first group of the plurality of substantially linear    segments intersects with the second group of the plurality of    substantially linear segments at angles of intersection, and wherein    the angles of intersection are in the range of about 70 degrees to    about 110 degrees.

Test Methods Air Permeability Test Method

The Air Permeability Test is used to determine the level of air flow incubic feet per minute (cfm) through a forming belt. The Air PermeabilityTest is performed on a Texas Instruments model FX3360 Portair AirPermeability Tester, available from Textest AG, Sonnenbergstrasse 72, CH8603 Schwerzenbach, Switzerland. The unit utilizes a 20.7 mm orificeplate for air permeability ranges between 300-1000 cfm. If airpermeability is lower than 300 cfm the orifice plate needs to bereduced; if higher than 1000 cfm the orifice plate needs to beincreased. Air permeability can be measured in localized zones of aforming belt to determine differences in air permeability across aforming belt.

Test Procedure

-   -   1. Power on the FX3360 instrument.    -   2. Select a pre-determined style having the following setup:        -   a. Material. Standard        -   b. Measurement Property: Air Permeability (AP)        -   c. Test Pressure: 125 Pa (pascals)        -   d. T-factor: 1.00        -   e. Test point pitch: 0.8 inch.    -   3. Position the 20.7 mm orifice plate on the top side of the        forming belt (the side with the three-dimensional protrusions)        at the position of interest.    -   4. Selecting “Spot Measurement” on the touch screen of the        testing unit.    -   5. Reset the sensor prior to measurement, if necessary.    -   6. Once reset, select the “Start” button to begin measurement.    -   7. Wait until the measurement stabilizes and record the cfm        reading on the screen.    -   8. Select the “Start” button again to stop measurement.

Basis Weight Test

Basis weight of the nonwoven webs described herein may be determined byseveral available techniques, but a simple representative techniqueinvolves taking an absorbent article or other consumer product, removingany elastic which may be present and stretching the absorbent article orother consumer product to its full length. A punch die having an area of45.6 cm² is then used to cut a piece of the nonwoven web (e.g.,topsheet, outer cover) from the approximate center of the absorbentarticle or other consumer product in a location which avoids to thegreatest extent possible any adhesive which may be used to fasten thenonwoven web to any other layers which may be present and removing thenonwoven web from other layers (using cryogenic spray, such asCyto-Freeze, Control Company, Houston, Tex., if needed). The sample isthen weighed and dividing by the area of the punch die yields the basisweight of the nonwoven web. Results are reported as a mean of 5 samplesto the nearest 0.1 gram per square meter (gsm).

Pattern Analysis Test

Area Variability and Shape Variability are obtained by analysis of arepeat unit of a pattern imparted to a nonwoven web by bonding,embossing, hydroentangling, or by a structured forming belt therebycreating a visually discernible pattern of three-dimensional featurescomprising one or more first regions, or a plurality of first regions,and a plurality of individual discrete second regions. For the purposesof this method, all patterns and distances are taken to be based on theprojection of the bonding, embossing, hydroentangling, or structuredforming belt pattern onto a two-dimensional plane.

A test region is identified as the region containing a single distinctrepeating pattern. If the test region does not contain a repeat unit,then the entire test region is analyzed as a single repeat unit. Asingle repeat unit (hereafter “SRU”) (for subsequent dimensionalmeasurement) within the test region having the repeating patterncomprising the plurality of repeating units is defined as follows. Anarbitrary point within the pattern is identified, referred to hereafteras the “chosen point” (hereafter “CP”). Any other point in the testregion recognized to be in an equivalent position based on thetranslational symmetry of the repeat units is referred to as an“equivalent point” (hereafter “EP”). The SRU is defined as the set ofpoints that are closer (via Euclidean distance) to the center of the CPthan to the center of any other EP in the test region. The SRUidentified for measurement must not touch the edge of the test region.After finding all points within the SRU, if it is found that the SRUtouches the edge of the test region, this procedure is repeated with analternative CP. The process is repeated until a SRU that does not touchthe edge of the test region is identified.

One approach to determining the set of points of a SRU is based onidentifying a polygonal boundary. Referring to FIG. 33, the boundary ofthe SRU is the convex polygon formed by the intersection of linesegments that immediately border the topsheet region containing the CP.The line segments are identified from lines drawn perpendicular to themidpoint of lines connecting the center of the CP to the center of allneighboring and nearby EP.

Referring to FIG. 17, the SRU length (L) is defined as the feretdiameter parallel to the longitudinal axis of the absorbent article, andthe SRU width (W) is defined as the feret diameter parallel to thelateral axis of the absorbent article. The feret diameter is thedistance between two parallel lines, both of which are tangential to theboundary of the SRU, and is recorded to the nearest 0.1 mm.

The boundaries of the individual discrete second regions bounded by andcontained within the SRU are identified. A region boundary may bevisually discernable due to changes in texture, elevation, or thickness.The boundary of a region may also be identified by visual discernment ofdifferences in intensive properties when compared to other regionswithin the SRU. For example, a second region boundary may be identifiedby visually discerning a thickness difference when compared to anadjacent first region within the SRU. Any of the intensive propertiesmay be used to discern second region boundaries on either the physicalsample itself of any of the micro-CT intensive property images. Theperimeters and areas of each of the second regions is recorded, as wellas, the total count of the number of the identified irregular andvarying second regions contained within the SRU.

Area Variability is the ratio of the area mean absolute deviation aroundthe mean to the mean area expressed as a percentage and is calculatedaccording to the following equation:

${{Area}\mspace{14mu} {Variability}} = {\frac{\frac{1}{n}{\sum\limits_{i = 1}^{n}\; {{x_{i} - \overset{\_}{x}}}}}{\overset{\_}{x}} \times 100}$

Where n is the number of individual second regions, x_(i) are theindividual second region areas, and x is the arithmetic mean of all ofthe areas. The Area Variability is recorded to the nearest wholepercent.

A shape complexity value is the ratio of a second region's perimetersquared to its area, and is calculated according to the followingequation:

${{shape}\mspace{14mu} {complexity}} = \frac{{perimeter}^{2}}{area}$

Shape Variability is the ratio of the shape complexity mean absolutedeviation around the mean to the mean shape complexity expressed as apercentage, and is calculated according to the following equation:

${{Shape}\mspace{14mu} {Variability}} = {\frac{\frac{1}{n}{\sum\limits_{i = 1}^{n}\; {{y_{i} - \overset{\_}{y}}}}}{\overset{\_}{y}} \times 100}$

Where n is the number of individual second regions, y_(i) are theindividual second region shape complexity values, and y is thearithmetic mean of all of the shape complexity values. The ShapeVariability is recorded to the nearest whole percent.

The percent area of the second regions within a repeat unit iscalculated by first measuring the total interior area of the SRU. Theareas of all the individual second regions, or portions thereof, locatedwithin the SRU are identified, summed together, and then divided by thetotal area of the SRU. The percent area of the second regions iscalculated according to the following equation:

${\% \mspace{14mu} {Area}\mspace{14mu} {of}\mspace{14mu} {Second}\mspace{14mu} {Regions}} = {\frac{\begin{matrix}{{Sum}\mspace{14mu} {of}\mspace{14mu} {Individual}} \\{{Second}\mspace{14mu} {Region}\mspace{14mu} {Areas}}\end{matrix}}{{Area}\mspace{14mu} {of}\mspace{14mu} {SRU}} \times 100\%}$

The percent area of the second regions is recorded to the nearest wholepercent.

The percent area of the first region within the repeat unit iscalculated according to the following equation:

% Area of First Region=100%−% Area of Second Regions

Repeat this procedure on five separate and distinct repeat unit areas.Report each of the measurements as the arithmetic mean of the fivereplicates.

Micro-CT Intensive Property Measurement Method

The micro-CT intensive property measurement method measures the basisweight, thickness and volumetric density values within visuallydiscernable regions of a substrate sample. It is based on analysis of a3D x-ray sample image obtained on a micro-CT instrument (a suitableinstrument is the Scanco pCT 50 available from Scanco Medical AG,Switzerland, or equivalent). The micro-CT instrument is a cone beammicrotomograph with a shielded cabinet. A maintenance free x-ray tube isused as the source with an adjustable diameter focal spot. The x-raybeam passes through the sample, where some of the x-rays are attenuatedby the sample. The extent of attenuation correlates to the mass ofmaterial the x-rays have to pass through. The transmitted x-rayscontinue on to the digital detector array and generate a 2D projectionimage of the sample. A 3D image of the sample is generated by collectingseveral individual projection images of the sample as it is rotated,which are then reconstructed into a single 3D image. The instrument isinterfaced with a computer running software to control the imageacquisition and save the raw data. The 3D image is then analyzed usingimage analysis software (a suitable image analysis software is MATLABavailable from The Mathworks, Inc., Natick, Mass., or equivalent) tomeasure the basis weight, thickness and volumetric density intensiveproperties of regions within the sample.

Sample Preparation:

To obtain a sample for measurement, lay a single layer of the drysubstrate material out flat and die cut a circular piece with a diameterof 30 mm.

If the substrate material is a layer of an absorbent article, forexample a topsheet, outer cover nonwoven web, acquisition layer,distribution layer, or another component layer; tape the absorbentarticle to a rigid flat surface in a planar configuration. Carefullyseparate the individual substrate layer from the absorbent article. Ascalpel and/or cryogenic spray (such as Cyto-Freeze, Control Company,Houston Tex.) can be used to remove a substrate layer from additionalunderlying layers, if necessary, to avoid any longitudinal and lateralextension of the material. Once the substrate layer has been removedfrom the article proceed with die cutting the sample as described above.

If the substrate material is in the form of a wet wipe, open a newpackage of wet wipes and remove the entire stack from the package.Remove a single wipe from the middle of the stack, lay it out flat andallow it to dry completely prior to die cutting the sample for analysis.

A sample may be cut from any location containing the visuallydiscernible zone to be analyzed. Within a zone, regions to be analyzedare ones associated with a three-dimensional feature defining amicrozone. The microzone comprises a least two visually discernibleregions. A zone, three-dimensional feature, or microzone may be visuallydiscernable due to changes in texture, elevation, or thickness. Regionswithin different samples taken from the same substrate material may beanalyzed and compared to each other. Care should be taken to avoidfolds, wrinkles or tears when selecting a location for sampling.

Image Acquisition:

Set up and calibrate the micro-CT instrument according to themanufacturer's specifications. Place the sample into the appropriateholder, between two rings of low density material, which have an innerdiameter of 25 mm. This will allow the central portion of the sample tolay horizontal and be scanned without having any other materialsdirectly adjacent to its upper and lower surfaces. Measurements shouldbe taken in this region. The 3D image field of view is approximately 35mm on each side in the xy-plane with a resolution of approximately 5000by 5000 pixels, and with a sufficient number of 7 micron thick slicescollected to fully include the z-direction of the sample. Thereconstructed 3D image resolution contains isotropic voxels of 7microns. Images are acquired with the source at 45 kVp and 133 μA withno additional low energy filter. These current and voltage settings maybe optimized to produce the maximum contrast in the projection data withsufficient x-ray penetration through the sample, but once optimized heldconstant for all substantially similar samples. A total of 1500projections images are obtained with an integration time of 1000 ms and3 averages. The projection images are reconstructed into the 3D image,and saved in 16-bit RAW format to preserve the full detector outputsignal for analysis.

Image Processing:

Load the 3D image into the image analysis software. Threshold the 3Dimage at a value which separates, and removes, the background signal dueto air, but maintains the signal from the sample fibers within thesubstrate.

Three 2D intensive property images are generated from the threshold 3Dimage. The first is the Basis Weight Image. To generate this image, thevalue for each voxel in an xy-plane slice is summed with all of itscorresponding voxel values in the other z-direction slices containingsignal from the sample. This creates a 2D image where each pixel now hasa value equal to the cumulative signal through the entire sample.

In order to convert the raw data values in the Basis Weight Image intoreal values a basis weight calibration curve is generated. Obtain asubstrate that is of substantially similar composition as the samplebeing analyzed and has a uniform basis weight. Follow the proceduresdescribed above to obtain at least ten replicate samples of thecalibration curve substrate. Accurately measure the basis weight, bytaking the mass to the nearest 0.0001 g and dividing by the sample areaand converting to grams per square meter (gsm), of each of the singlelayer calibration samples and calculate the average to the nearest 0.01gsm. Following the procedures described above, acquire a micro-CT imageof a single layer of the calibration sample substrate. Following theprocedure described above process the micro-CT image, and generate aBasis Weight Image containing raw data values. The real basis weightvalue for this sample is the average basis weight value measured on thecalibration samples. Next, stack two layers of the calibration substratesamples on top of each other, and acquire a micro-CT image of the twolayers of calibration substrate. Generate a basis weight raw data imageof both layers together, whose real basis weight value is equal to twicethe average basis weight value measured on the calibration samples.Repeat this procedure of stacking single layers of the calibrationsubstrate, acquiring a micro-CT image of all of the layers, generating araw data basis weight image of all of the layers, the real basis weightvalue of which is equal to the number of layers times the average basisweight value measured on the calibration samples. A total of at leastfour different basis weight calibration images are obtained. The basisweight values of the calibration samples must include values above andbelow the basis weight values of the original sample being analyzed toensure an accurate calibration. The calibration curve is generated byperforming a linear regression on the raw data versus the real basisweight values for the four calibration samples. This linear regressionmust have an R2 value of at least 0.95, if not repeat the entirecalibration procedure. This calibration curve is now used to convert theraw data values into real basis weights.

The second intensive property 2D image is the Thickness Image. Togenerate this image the upper and lower surfaces of the sample areidentified, and the distance between these surfaces is calculated givingthe sample thickness. The upper surface of the sample is identified bystarting at the uppermost z-direction slice and evaluating each slicegoing through the sample to locate the z-direction voxel for all pixelpositions in the xy-plane where sample signal was first detected. Thesame procedure is followed for identifying the lower surface of thesample, except the z-direction voxels located are all the positions inthe xy-plane where sample signal was last detected. Once the upper andlower surfaces have been identified they are smoothed with a 15×15median filter to remove signal from stray fibers. The 2D Thickness Imageis then generated by counting the number of voxels that exist betweenthe upper and lower surfaces for each of the pixel positions in thexy-plane. This raw thickness value is then converted to actual distance,in microns, by multiplying the voxel count by the 7 μm slice thicknessresolution.

The third intensive property 2D image is the Volumetric Density Image.To generate this image, divide each xy-plane pixel value in the BasisWeight Image, in units of gsm, by the corresponding pixel in theThickness Image, in units of microns. The units of the VolumetricDensity Image are grams per cubic centimeter (g/cc).

Micro-CT Basis Weight, Thickness and Volumetric Density IntensiveProperties:

Begin by identifying the region to be analyzed. A region to be analyzedis one associated with a three-dimensional feature defining a microzone.The microzone comprises a least two visually discernible regions. Azone, three-dimensional feature, or microzone may be visuallydiscernable due to changes in texture, elevation, or thickness. Next,identify the boundary of the region to be analyzed. The boundary of aregion is identified by visual discernment of differences in intensiveproperties when compared to other regions within the sample. Forexample, a region boundary can be identified based by visuallydiscerning a thickness difference when compared to another region in thesample. Any of the intensive properties can be used to discern regionboundaries on either the physical sample itself of any of the micro-CTintensive property images. Once the boundary of the region has beenidentified, draw an oval or circular “region of interest” (ROI) withinthe interior of the region. The ROI should have an area of at least 0.1mm2, and be selected to measure an area with intensive property valuesrepresentative of the identified region. From each of the threeintensive property images calculate the average basis weight, thicknessand volumetric density within the ROI. Record these values as theregion's basis weight to the nearest 0.01 gsm, thickness to the nearest0.1 micron and volumetric density to the nearest 0.0001 g/cc.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular forms of the present disclosure have been illustratedand described, it would be obvious to those skilled in the art thatvarious other changes and modifications can be made without departingfrom the spirit and scope of the present disclosure. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this present disclosure.

What is claimed is:
 1. A nonwoven web for an absorbent article, thenonwoven web comprising: a first surface; a second surface; and a repeatunit comprising: a visually discernible pattern of three-dimensionalfeatures on the first surface or the second surface, wherein thethree-dimensional features comprise one or more first regions and aplurality of second regions, and wherein the plurality of second regionscomprise 10 to 100 irregular varying regions, according to the PatternAnalysis Test.
 2. The nonwoven web for an absorbent article of claim 1,wherein the one or more first regions comprise a plurality ofsubstantially linear segments.
 3. The nonwoven web for an absorbentarticle of claim 1, wherein the plurality of second regions comprisingthe 10 to 100 irregular varying regions have an Area Variability ofgreater than 50%, but less than 150%, according to the Pattern AnalysisTest.
 4. The nonwoven web for an absorbent article of claim 1, whereinthe plurality of second regions comprising the 10 to 100 irregularvarying regions have a Shape Variability of greater than 20%, but lessthan 120%, according to the Pattern Analysis Test.
 5. The nonwoven webfor an absorbent article of claim 1, wherein at least some of the 10 to100 irregular varying regions comprise a peninsular shape.
 6. Thenonwoven web for an absorbent article of claim 1, wherein the pluralityof second regions comprising the 10 to 100 irregular varying regions arefree of the plurality of substantially linear segments.
 7. The nonwovenweb for an absorbent article of claim 1, wherein the one or more firstregions have an average intensive property having a first value, andwherein the plurality of second regions comprising the 10 to 100irregular varying regions have the average intensive property having asecond, different value.
 8. The nonwoven web for an absorbent article ofclaim 7, wherein the average intensive property is caliper, basisweight, or volumetric density.
 9. The nonwoven web for an absorbentarticle of claim 2, wherein the plurality of substantially linearsegments comprise a first group of the plurality of substantially linearsegments and a second group of the plurality of substantially linearsegments, wherein the first group of the plurality of substantiallylinear segments intersects with the second group of the plurality ofsubstantially linear segments at angles of intersection, and wherein theangles of intersection are in the range of about 70 degrees to about 110degrees.
 10. The nonwoven web for an absorbent article of claim 1,wherein the visually discernable pattern is embossed.
 11. The nonwovenweb for any absorbent article of claim 1, wherein the visuallydiscernable pattern is hydroentangled.
 12. The nonwoven web for anabsorbent article of claim 1, comprising a second visually discerniblepattern of three-dimensional elements on the first surface or the secondsurface and outside of the repeat unit, wherein each of thethree-dimensional elements define a microzone comprising a first regionand a second region.
 13. The nonwoven web for an absorbent article ofclaim 1, comprising a second visually discernible pattern ofthree-dimensional elements on the first surface or the second surfaceand outside of the repeat unit, wherein the three-dimensional elementscomprise one or more third regions and a plurality of fourth regions,and wherein the one or more third regions comprise a plurality ofsubstantially linear segments.
 14. The nonwoven web for an absorbentarticle of claim 1, wherein the nonwoven web is formed on a structuredforming belt.
 15. An absorbent article comprising the nonwoven web ofclaim
 1. 16. The absorbent article of claim 15, comprising: a liquidpermeable topsheet; a liquid permeable backsheet; and an absorbent corepositioned at least partially intermediate the topsheet and thebacksheet.
 17. The absorbent article of claim 16, wherein the topsheetcomprises the nonwoven web.
 18. The absorbent article of claim 16,comprising an outer cover nonwoven material in a facing relationshipwith the backsheet, wherein the nonwoven web comprises the outer covernonwoven material.
 19. A nonwoven web for an absorbent article, thenonwoven web comprising: a first surface; a second surface; and a repeatunit comprising: a visually discernible pattern of three-dimensionalfeatures on the first surface or the second surface, wherein thethree-dimensional features comprise one or more first regions and aplurality of second regions, and wherein the plurality of second regionshave an Area Variability of greater than 50%, but less than 150%,according to the Pattern Analysis Test.
 20. The nonwoven web for anabsorbent article of claim 19, wherein the plurality of second regionscomprise 10 to 100 irregular varying regions, according to the PatternAnalysis Test.
 21. The nonwoven web for an absorbent article of claim19, wherein the plurality of second regions have a Shape Variability ofgreater than 20%, but less than 120%, according to the Pattern AnalysisTest.
 22. The nonwoven web for an absorbent article of claim 21, whereinat least some of the plurality of second regions comprise a peninsularshape.